Power Wagon Registry (2005 and up)

Power Wagon Registry - Warn Winch Thermal Bypass

How-to by Peter Davey (pdavey) on Dodgetalk

After reading a few posts I decided to take a trip to my local NAPA auto parts to see if I could put together a bypass that looked pretty good and didn't cost an arm and a leg. I purchased item number 755-1598 a 2-Flat Electrical Connector - 12" Loop ($1.99) (similar to the connector that goes from the solenoids to the thermal protection switch) a few crimp ends and had some electical tape laying around the house. (All told less then $3.00)

1. Cut the 2-Flat Electrical Connector in half and leave about 2 inches of wire on both ends and Strip all 4 wires leaving the bare copper ends



2. Twist the ends of the black and white wires together



3. Use a 14-20 guage crimp ends and crimp them onto the ends of the combined wires



4. Finish with electrical tape to make more water resistant and a nicer finish



5. Separate the two ends on the winch



6. Plug the newly created bypasses onto each end (you likely don't need the end from the side going to the winch motor but I don't like to leave empty wires hanging.)